Industrial Training Report KSE LIMITED

CHAPTER 1

INTRODUCTION

1.1 KERALA SOLVENT EXTRACTIONS LIMITED

It was in 1963 that Kerala Solvent Extractions Ltd., now known as KSE Ltd., entered the
Solvent Extraction Industry, setting up the very first solvent extraction plant in Kerala. The
solvent extraction plant went on stream in 1972 and in 1976, a new plant was set up to
manufacture ready mixed cattle feed. KSE Limited is a public limited company with around
4500 shareholders. The shares are listed in Bombay Stock Exchange (BSE), Madras Stock
exchange (MSE), Cochin Stock Exchange (CSE) and National Stock Exchange (NSE) with an
arrangement with MSE. We are the largest manufacturer of compound cattle feed in private
sector in the country. The last three decades have seen KSE emerging as a leader in solvent
extraction and ready mixed cattle feed in the country. Today KSE commands the resources,
expertise and infrastructure to manufacture a range of livestock feed in high volumes, coconut oil
from coconut oil cake and refined edible oil. KSE has also entered in the field of milk
procurement and processing. KS Milk, KS Ghee and Vesta Ice Cream have become popular in
many districts in Kerala. Driven by a commitment to high standards of quality, KSE has not only
won customer confidence but also national recognition through several awards and accolades.
With modern manufacturing facilities spread over three states, KSE caters to the vast belt
stretching across Southern India and enjoys a significant presence in exports too. Since the early
days, KSE has endeavored to supply its products to customers through an extensive network of
dealers and retailers, which form a dedicated force behind the success of KSE. It is a matter of
pride that KSE is a household name today. With a strong commitment to customers and product
quality and being cost competitive, KSE stands poised to meet new challenges.

1.2MILESTONES OF SAGA OF SUCCESS:

 1972- The company started production in Irinjalakuda with a Solvent Extraction plant
with a capacity of 40 MTs per day

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 1976- A new plant was set up in Irinjalakuda to produce 50 MTs of ready mixed cattle
feed
 1983- A fully automatic new Cattle feed Plant started operation in Irinjalakuda Capacity
120 MTs per day
 1987- Cattle feed plant at Irinjalakuda capacity increased to 180 MTs per day
 1989– Solvent Extraction Plant of Swaminathapuram unit with a capacity of 120 MTs per
day started production.
 1990–Cattle feed production capacity at Swaminathapuram unit increased to 150 MTs
per day.
 1991– Palakkad Branch started.
 1994– Keyes Forte, the new feed supplement for cattle introduced.
Cattle feed production capacity at Swaminathapuram increased to 180 MTs per day.
 1995– Calicut Branch opened.
 1996– 240 TPD cattle feed Plant at Vedagiri in Kottayam District started operation.
Company renamed as KSE Limited. (Formerly Kerala Solvent Extractions Limited)
 1998– Company acquired its fourth manufacturing unit at Palakkad for manufacturing
Cattle feed.
 1999– A modern CHILDRENS’ PARK AND INFORMATION CENTRE was completed
at Irinjalakuda for the benefit of the Public. Company introduced K.S. Deluxe Plus the
Pelleted feed in HDPE bags for Kerala Market.
 2000– Company started production and marketing of Pasteurized Milk and Milk products
from Konikkara Dairy, Thrissur District, Kerala and Thalayuthu Dairy, PalaniTaluk,
Tamilnadu.
 2002– Cattle feed production at Irinjalakuda unit increased to 195 MTs per day.
VESTA Ice Cream launched.
 2003– Started production of Cattle feed in a leased plant at Edayar, Kalamassery.
Cattle feed production at the Swaminathapuram unit increased to 195 MTs per day.
 2004– Acquired Land from KINFRA for starting the new project of 200 TPD
Solvent Plant and 100 TPD Oil Physical Refining Plant at Kinfra Park, Koratty.
ISO 9001:2008 Accreditation for Irinjalakuda.

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 2005–Cattle feed Production capacity at the Irinjalakuda unit increased to 210 MTs per
day.
 Company acquired property at Mysore.
 ISO 9001:2008 accreditation for Vedagiri and Swaminathapuram units.
 2006– The 200 TPD Solvent Extraction Plant at Koratty commissioned.
100 TPD Physical Refining Plant at Koratty commissioned.
Solvent Plant at Irinjalakuda dismantled.
 2008– Ice cream production unit commissioned at Thalayuthu.
 2009 – Cattle Feed production capacity at Swaminathapuram increased to 200 MTs per
day. Commissioned Fractionation Plant at Koratty Commenced 500 TPD Fully State-of-
the-Art German Technology Animal Feed Plant at Irinjalakuda.
 2010 – Ice cream production unit at Vedagiri commissioned.

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CHAPTER 2

INDUSTRY PROFILE

2.1 CATTLE FEED INDUSTRY

In the past, the cattle population was in proportion to the amount of resource available to
feed them. But today things have changed and the natural feed available for the cattle has also
come down drastically. In addition to this the demand for the milk and milk product have also
been increasing ,thus making it absolutely necessary for rearing cattle which produce high yield.
From this arose the concept of producing cattle feed wherein there is no compromise over the
nutritional composition. The productivity of the cattle is limited of their genetic make-up, so high
quality compound feed (industry feed) may not necessarily generate a significant improvement in
productivity and this has hampered growth of the cattle feed industry because most farmers
reluctant to use compound fully. They compromise by using such field in proportions of 5to 6%,
making up the balance with their formulation.

According to Extract from Animal feeding safely, report of an FAQ expert consultation
present condition of cattle feed is worldwide, tonnage of feed exceeds 4 billion tons per annum
of which some 550 million tones are milled feeds. The largest portion of the billion tons of feed
involves subsistence farming on the Indian subcontinent and Asia. India is currently self-
sufficient livestock feeds and does not depend on imports. Instead, the country exports large
quantities of solvent extracted meals which are a major source of foreign exchange earnings.

2.2 COMPANY PROFILE

It was in 1963 that Kerala Solvent Extraction Limited now known as KSE Limited
entered the solvent extraction industry, setting up the very first solvent extraction plant in Kerala.
Although Kerala produces 80% of total copra produced in the country, large part of it was sold to
other states as copra itself and they were earning good profit when mills in Kerala wasn’t able to
get enough copra for their daily needs. When oil industry in other parts of the country was
thriving, in Kerala it was struggling. So they understood the need for modernization of their
mills. At that time Dr.P.S.Loknathan committee setup to study the feasibility of starting new

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industries in Kerala, recommended the establishment of three solvent extraction plants. And one
of them was in Thrissur district. The oil mill owners in and around Irinjalakuda, who were
thinking in similar lines saw the opportunity and took the initiative to establish a solvent
extraction unit, Thus KSE was established. Thus in 1976 KSE LTD entered the cattle feed
industry, setting up new plant manufacturing ready mixed cattle feed. The last 3 decades have
been KSE LTD emerging as the leader in ready mixed cattle feed in the country. Today KSE
LTD commands the resources, expertise and infrastructure of manufacture arrange of livestock
feed in high volumes, driven by commitment to high quality. On the road to success, there were
many hurdles. Initially, the mobilization of capital posed the greatest challenge. The future
looked grim. But determination and optimism paid off. Thus on 25 September 1963 the Kerala
Solvent Extraction Limited was registered as a public limited company. The solvent extraction
plant went on stream in 1972 and in 1976 a new plant was set up to manufacture ready mixed
cattle feed, which was pioneering step. Since then there was no looking back. The last three
decades have seen KSE emerging as the leader in solvent extraction and ready mixed cattle feed
in the country. And through these years of consolidation and diversification, KSE has created a
niche for itself. Today KSE commands the resources, expertise and infrastructure to manufacture
a range of livestock feed, in high volumes, coconut oil from coconut oil cake, and refined edible
oil.

2.3PRODUCT PROFILE

1. K.S Cattle feed

The company produces7 types of cattle feed.

 K.S Special
 K.S Super
 K.S Ordinary
 K.S Deluxe pellet
 K.S Deluxe plus pellet
 K.S Premium plus pellet
 K.S supreme-Bypass protein feed with ISI mark

2. K.S Supreme (Refined Sunflower Oil)

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3. Jersey copra cake- The deoiled coconut cake, produced out of Coconut oil cake using Solvent
Extraction process is made pure by desolventizing.

4. K.S Forte –It is a Feed Supplement for cattle. It contains Vitamins A, D3, and E and all the
required trace minerals at recommended quantities.

5. K.S Mineral mixture

6. Milk Products

 K.S Milk
 K.S Ghee
 K.S Curd
 K.S Butter Milk
 Vesta ice cream

2.4 ORGANIZATIONAL STRUCTURE

Figure No. 2.1 Organizational Charts.

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Organizational structure shows the Board of Directors, WhoTimeDirector, Executive

Director,ProgramManager,QualityManager,MarketingManager,HRManager,PurchaseManager,F
inanceManager,GeneralManager,ManagingDirector,ExecutiveOfficer,SecurityOfficer,Customer
Service,ChiefNutritionist,AssistantSalesManager,Engineer,ExecutiveOfficer,ShareDepartment,A
ssistantFinanceManager,AssistantA/cManager,Clerk,SalesRepresentatives,LabAttainder,Worker
s,SecurityGuard, Executives etc.

2.5 INDUSTRY SERVICES

2.5.1 Internal Control

The system of internal controls may define as the organizational plan and all the methods
and procedure adopted by the management of the entity to assist in achieving.

 Timely preparation of reliable financial information

 Accuracy and completeness of accounting records
 Prevention and completeness of accounting records
 Safeguarding asset
 Adherence to management policies
 Orderly and efficient conduct of its business.

2.5.2 Sales Division

This is headed by an assistant manager .As mentioned earlier all the dealers are
controlled by the company directly .all orders from the dealers all over the state are received by
him. In consultation with the production managers of the various plants, He makes the allotment.
The allotment is made from the various plants he makes the allotment .the allotment is making
from the various plants depending upon the availability and proximity to the dealer. The manager
at the sales division informs the production manager about the demand for the various products
so as to plan production accordingly.

2.5.3 Complaints and Customer Service

This division is headed by an assistant manager .Since KSE Limited has network of
dealers directly under their control, maintenance of this network is very difficult .The dealer area
is very small and closely situated. Overlapping of agencies is a problem. Complaints regarding

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agencies will reach this department. The complaints are studied and necessary actions are taken.
Similarly, companies regarding the product are also taken care here. As and when a complaint is
received, inspection team is sent to the specified area and details are collected and necessary
actions will be taken immediately.

2.6 DEPARTMENT DETAILS

In KSE the work activities that are similar and logically connected are grouped to form
departments. At present there are seven departments in the organization. They are as follows.

 Finance Department
 Marketing Department
 Human Resource Department
 Production Department
 Purchase Department
 Store Department
 Quality Department

The study was confined only to four departments of the firm due to lack of time. The
departments covered under the study were marketing, finance, quality control.

2.6.1 Finance Department

Figure No. 3.2Finance Department Structure

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2.6.2Production Department

Production is the functional area responsible for turning inputs into finished outputs
through a series of production processes. The Production Manager is responsible for making sure
that raw materials are provided and made into finished goods effectively. He or she must make
sure that work is carried out smoothly, and must supervise procedures for making work more
efficient and more enjoyable. In a manufacturing company the production function may be split
into five sub-functions:

 The production and planning department will set standards and targets for each section of
the production process. The quantity and quality of products coming off a production line
will be closely monitored. In businesses focusing on lean production, quality will be
monitored by all employees at every stage of production, rather than at the end as is the
case for businesses using a quality control approach.
 The purchasing department will be responsible for providing the materials, components
and equipment required to keep the production process running smoothly. A vital aspect
of this role is ensuring stocks arrive on time and to the right quality.
 The stores department will be responsible for stocking all the necessary tools, spares, raw
materials and equipment required to service the manufacturing process. Where sourcing
is unreliable, buffer stocks will need to be kept and the use of computerized stock control
systems helps keep stocks at a minimal but necessary level for production to continue
unhindered.
 The design and technical support department will be responsible for researching new
products or modifications to existing ones, estimating costs for producing in different
quantities and by using different methods. It will also be responsible for the design and
testing of new product processes and product types, together with the development of
prototypes through to the final product. The technical support department may also be
responsible for work study and suggestions as to how working practices can be improved.
 The works department will be concerned with the manufacture of products. This will
include the maintenance of the production line and other necessary repairs. The works
department may also have responsibility for quality control and inspection.

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2.6.3 Quality Control Department

Main task of this department is to completely analyze the raw material and point out
defect in it. Normally every week the nutrition has to alter the formula of cattle feed which in
time governed the availability, rate and quality of raw material. Quality departments, such as
Quality Control (QC) or Quality Assurance (QA) cannot inspect quality into the product. The
Quality Departments exist as an audit function within the manufacturing and packaging areas.
According to NNFA GMPs, the responsibilities for QC are as follows.

 Approve or reject all procedures, specifications, methods, and results.

 Approve or reject all raw materials, packaging materials, labeling and finished products.
 Review all production records for accuracy and completeness before approving for
distribution.
 Establish procedures for revising procedures, formulas, etc.
 Approve changes to procedures, formulas, etc.
 Ensure that the latest revision is being used at all times.
 Perform all the required tests to ensure identity, purity, potency and composition, and to
ensure that products are not contaminated or adulterated

2.7 MMCP TECHNOLOGY

The technology of MMCP defines 4 processes which include:

2.7.1 Milling

This is being used for ensuring that all the granules are grinded, screened 3 mm sieve.
The materials feed into grinder are powered and it passes through the screen provided at the
bottom side of the grinding chamber. The hammer mills at 30 tons per hour together are used.

2.7.2 Mixing

The raw material will be mixed thoroughly by using horizontal mixer. Capacity of this
mixer is 6m.

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2.7.3 Cooking

The steam for cooking is produced using 3 million tons boiler. The mixer orhomogeniser
carry out a strong mixing while the mash is moved forward and added with dry saturated steam.
The cooking is carried out at a temperature of 80 degree Celsius using a high pressure dry
saturated steam.

2.7.4 Pelleting

The pellet mill dye by rotating drags the mixture of mash and steam towards the roller.
Which press it and consequently compel to pass through the hole of the dye. It increases the
density of the mixture, which together with heat generated by the saturated steam facilitates the
extraction of the pellet.

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CHAPTER 3

INDUSTRY EQUIPMENTS

3.1 BOILER

FigureNo.3.1 Simple Boiler

A Boiler is a closed vessel in which water or other fluid heated. The fluid does not
necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or
heating applications including central heating, boiler based power generation, cooking, and
sanitation.

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3.2 MATERIAL

The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically
of wrought iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of
boilers due to corrosion and stress corrosion cracking. However, ferrite stainless steel is often
used in super heater sections that will not be exposed to boiling water, and electrically-heated
stainless steel shell boilers are allowed under the European Pressure Equipment Directive for
production of steam for sterilizers and disinfectors.

In live steam models, copper or brass is often used because it is more easily fabricated in
smaller size boilers. Historically, copper was often used for fireboxes (particularly for steam),
because of its better formability and higher thermal conductivity; however, in more recent times,
the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as
steel) are used instead.

3.3 FUEL

The source of heat for a boiler is combustion of any of several fuels, such
as wood, coal, oil, or natural gas. Electric steam boilers use resistance or immersion-type heating
elements. Nuclear fission is also used as a heat source for generating steam, either directly
(BWR) or, in most cases, in specialized heat exchangers called steam generators (PWR). Heat
recovery steam generators (HRSGs) use the heat rejected from other processes such as gas
turbine.

3.4 INDUSTRIAL ACCESSORIES

3.4.1 Steam Accessories

 Main steam stop valve

 Steam traps
 Main steam stop/Check valve: It is used on multiple boiler installations.

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3.4.2 Combustion Accessories

 Fuel oil system: fuel oil heaters

 Gas system
 Coal system
 Soot blower

3.4.3 Other Essential Parts

 Pressure gauges
 Feed pumps
 Fusible plug
 Inspectors test pressure gauge attachment
 Name plate
 Registration plate

Figure No. 3.2 Boiler Working

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CHAPTER 4

WORKING SYSTEM

4.1 WATER COOLING SYSTEM

 Process cooling water system (PCWS)

 Factory cooling water system (FCWS)
 Compressor cooling water system (CCWS)

Table No. 4.1 Water cooling system specifications

Supply Pressure
Types of Water Supply Temperature
(Kg/Cm2)

PCWS 40oC 23

FCWS 31oC 4.5

Chilled Water 12.8oC 4.5

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4.2 BOILER HOUSE

Table No. 4.2 Features of Boiler House

Serial Heating Working Maximum

Capacity
Make Surface Area Burner Ecco / APH Pressure Pressure
No. TPH
m2 (Kg/Cm2) (Kg/Cm2)

1 Thermax 14 305 Weigshaupt Air Pre-Heater 17.0 21.5

2 IAEC-1 10 220 AR-45 Type Economizer 17.0 17.5

3 IAEC-2 14 315 Hi-Cal SR-50 Economizer 17.0 21.5

4 IAEC-3 10 242 Weigshaupt Economizer 17.0 17.5

Wester
5 14 315 Weigshaupt Economizer 17.0 17.5
Work

4.3 WATER QUALITY MEASURES

 Freedom from scale

 Freedom from corrosion

 Good quality steam

 Safety

 Cooling system

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4.4 BOILER WATER SYSTEM

Figure No. 4.1 Boiler Water Systemkey

4.4.1 Boiler Water Treatment

4.4.1.1 Purpose

Statistically 75% of all boiler water problems manifested in the boiler have a root cause
in the pretreatment system.

4.4.1.2 Process

Walk through the processes, key factors, monitoring, and operational impacts of pre-
treatment systems.

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4.4.1.3 Payoff

Cleaner boilers, increased energy efficiency, reduced maintenance time and costs,
increased plant production time and capacity.

Figure No. 4.2 Cross section of boiler

4.5 BATCHING

Figure No. 4.3 Batching Layout

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Batch production is a technique used in manufacturing, in which the object in question is

created stage by stage over a series of workstations, and different batches of products are made.
With job production (one-off production) and flow production (continuous production) it is one
of the three main production methods.

4.5.1 Types of Batching

 In-line Batching
 Compartment Batcher
 Star Batcher

4.6 INTERNAL CONTROL SYSTEMS AND THEIR ADEQUACY

There are adequate internal control systems in vogue in all spheres of operations of the
Company so as to ensure safety to its assets against loss. These internal controls are designed in
such a way to ensure adequate accounting and financial controls. The internal control system is
being continuously reviewed by the management and adequate steps are taken for improvement,
wherever felt.To control the undesirable effects of industrial livestock production, the Livestock
and Environment authors proposed.
 To establish zoning for industrial production systems.
 To bring animal densities in line with the absorptive capacity of land and water, through
quota systems, as already imposed in many parts of the world.
 To prescribe regulations for waste control from processing and industrial production
units, and use of noxious substances, management practices, and labeling.
They also point out that there may be environmental benefits of industrial production
systems. Firstly, the rapid development of pig and poultry systems helps to reduce total feed
requirements of the global livestock sector to meet a given demand.

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CHAPTER 5
CONCLUSION

The training at KSE LIMITED Irinjalakuda was extremely helpful considering work
experience and knowledge. It gave me introduction to industrial field. I was glad to see
implementation of theoretical knowledge in actual practice which until recently was book
knowledge for me. I was glad to see the various machining processes, Rejection analysis, Quality
control techniques, and hydraulically operated devices. To conclude, this industrial training has
helped me a lot to understand the working of an industry. It also exposed me to industrial life,
which is surely helpful for lifetime. To maintain top position in the industry utilize the new
technological changes for the benefits of the company. The most important objectives are
 To produce, manufacture, extract purchase, refine prepare import, export, sell and
generally to deal in oil bearing materials to carry on business of the refining the
hydrogenation of oil and manufacturing of byproducts there from and of trades connected
there with.
 To acquire erect construct establish .operate and maintain oil mills, extraction plants,
ghee plants and workshop.

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